Joint formation in cement-based structures

ABSTRACT

A joint-forming system includes a first smoothing plate, a second smoothing plate coupled with the first smoothing plate so as to form an interior angle and an exterior angle therewith, a first bracket extending between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle, a second bracket extending between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle. A handle extends between the first bracket and the second bracket. One or more blades are configured to extend along the exterior angle at a crest thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of U.S. Provisional Application No. 62/730,105 filed on Sep. 12, 2018, pending, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The disclosure pertains to finishing of binders, binder aggregates and mortars.

SUMMARY

The disclosure describes a joint-forming apparatus. The joint forming apparatus includes a first smoothing plate, a second smoothing plate coupled with the first smoothing plate so as to form an interior angle and an exterior angle therewith, a first bracket extending between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle, a second bracket extending between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle, a handle extending between the first bracket and the second bracket and a blade extending along the exterior angle at a crest thereof.

The disclosure also describes a joint-forming system. The joint-forming system includes a first smoothing plate, a second smoothing plate coupled with the first smoothing plate so as to form an interior angle and an exterior angle therewith, a first bracket extending between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle, a second bracket extending between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle, a handle extending between the first bracket and the second bracket and a first blade configured to extend along the exterior angle at a crest thereof.

The disclosure also describes a method for manufacturing a joint-forming apparatus. The method includes from a construction material, cutting a blade to a first length, milling nose angles into a nose of the blade, milling an elongate concavity in a top of the blade, milling an angled first side into the blade, milling an angled second side into the blade, milling a radius into the bottom edge of the blade, milling a radius into the nose of the blade, coupling a first smoothing plate with a second smoothing plate so as to form an interior angle and an exterior angle therebetween and coupling the blade to the first and second smoothing plates.

BRIEF DESCRIPTION OF THE FIGURES

The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the disclosure, example constructions are shown in the drawings. However, the disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those having ordinary skill in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

Embodiments of the disclosure will now be described, by way of example only, with reference to the following drawings wherein:

FIG. 1 illustrates a bottom perspective view of an example joint-forming apparatus.

FIG. 2 illustrates a top view of the example joint-forming apparatus of FIG. 1.

FIG. 3 illustrates a left side view of the example joint-forming apparatus of FIGS. 1-2.

FIG. 4 illustrates a rear view of the example joint-forming apparatus of FIGS. 1-3.

FIG. 5 illustrates a front view of the example joint-forming apparatus of FIGS. 1-4.

FIGS. 6A-6C illustrate top, side and front views of an example blade configured for use as part of the joint-forming apparatus of FIGS. 1-5.

FIG. 7 illustrates an example joint-forming apparatus as part of an example joint-forming system.

FIG. 8 illustrates a flow of an example method for manufacturing a joint-forming apparatus.

FIG. 9 illustrates a method of using the example joint-forming apparatus of FIGS. 1-5.

DETAILED DESCRIPTION

The following detailed description illustrates embodiments of the disclosure and manners by which they can be implemented. Although the best mode of carrying out disclosed apparatus, systems and methods has been described, those of ordinary skill in the art would recognize that other embodiments for carrying out or practicing disclosed apparatus, systems and methods are also possible.

It should be noted that the terms “first”, “second”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Further, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

Disclosed apparatus, systems and methods facilitate finishing concrete while cement is hardening.

Disclosed apparatus, systems and methods substantially eliminate, or at least partially address, problems in the prior art, for example, by enabling carving into the full horizontal length of a newly poured, uncured concrete step to create a joint at the 90-degree angle where the riser and tread meet. This joint may be formed sufficiently deep to hide cracks and/or prevent cracks from spreading.

Additional aspects, advantages, features and objects of the disclosure will be made apparent from the drawings and the detailed description of the illustrative embodiments construed in conjunction with the appended claims that follow. It will be appreciated that described features are susceptible to being combined in various combinations without departing from the scope of the disclosure as defined by the appended claims.

Referring now to the drawings, FIGS. 1-5 illustrate an example joint-forming apparatus 1000. Joint-forming apparatus 1000 includes a first smoothing plate 1100 and a second smoothing plate 1200 coupled with first smoothing plate 1100 so as to form an interior angle 1110 (FIG. 4) and an exterior angle 1210 therewith. A first bracket 1300 extends between first smoothing plate 1100 and second smoothing plate 1200 so as to span a portion of interior angle 1110. A second bracket 1400 extends between first smoothing plate 1100 and second smoothing plate 1200 so as to span a portion of interior angle 1110. A handle 1500 extends between first bracket 1300 and second bracket 1400 and a blade 1600, which may resemble a ship's hull, extends along exterior angle 1210 at an apex or crest 1215 (FIG. 5) thereof.

First and second smoothing plates 1100 and 1200 may be formed separately and coupled together or may be integral. First and second smoothing plates 1100 and 1200 slide into and/or over the concrete and create a smooth finish while helping guide blade 1600 into the concrete. While interior angle 1110 may take any of a variety of measures, in an example, interior angle 1110 may be about 90 degrees. First and second smoothing plates 1100 and 1200 may be formed from or otherwise include any of a variety of materials including but not limited one or more metals and combinations thereof. In an example, smoothing plates 1100 and 1200 are formed from steel.

First bracket 1300 may further include a first leg 1310 coupled with first smoothing plate 1100 and a second leg 1320 coupled with second smoothing plate 1200 and first and second legs 1310 and 1320 of first bracket 1300 may form an interior angle 1330 opposite interior angle 1110 between first and second smoothing plates 1100 and 1200. Interior angle 1330 formed by first and second legs 1310 and 1320 of first bracket 1300 may be equal in measure to interior angle 1110 formed by first and second smoothing plates 1100 and 1200. First and second legs 1310 and 1320 of first bracket 1300 may be coupled together at a first joint 1340 or may comprise an integral angle iron.

Second bracket 1400 may further include a first leg 1410 coupled with first smoothing plate 1100 and a second leg 1420 coupled with second smoothing plate 1200 and the first and second legs 1410 and 1420 of second bracket 1400 may form an interior angle 1430 opposite interior angle 1110 between first and second smoothing plates 1100 and 1200. Interior angle 1430 formed by first and second legs 1410 and 1420 of second bracket 1400 may be equal in measure to interior angle 1110 formed by first and second smoothing plates 1100 and 1200. First and second legs 1410 and 1420 of second bracket 1400 may be coupled together at a second joint 1440 or may comprise an integral angle iron.

In an example, first and second brackets 1300 and 1400 may be formed from or otherwise include any of a variety of materials including but not limited one or more metals and combinations thereof. In an example, brackets 1300 and 1400 are formed from steel. Further, first and second brackets 1300 and 1400 may take any of a variety of shapes suitable to span interior angle 1110 and support handle 1500 distal from smoothing plates 1100 and 1200. For example, brackets 1300 and 1400 may take a rectilinear configuration shown by way of example or a curvilinear configuration.

In an example, handle 1500 extends between first bracket 1300 and second bracket 1400. For example, handle 1500 may extend from joint 1340 to second joint 1440 and be coupled thereto by one or more fasteners such as screws. Handle 1500 may exhibit any of a variety of shapes and/or dimensions suitable for spanning first and second brackets 1300 and 1400 and providing a convenient and comfortable feature for a user to grasp during tool use. Shapes and/or dimensions include but are not limited to a circular cylindrical form such as a dowel. Handle 1500 may be formed from or include any of a variety of materials including but not limited to wood, rubber, plastics and combinations thereof.

FIG. 6A illustrates a top view of, FIG. 6B illustrates a side view of and FIG. 6C illustrates a front view of side an example blade 1600 configured for use as part of a joint-forming apparatus 1000 or joint forming system 2000. Blade 1600 may be configured to carve a notch in uncured concrete. For example, blade 1600 may be configured to carve a joint between an uncured concrete stair tread and an uncured concrete stair riser.

Blade 1600 may extend along crest 1215 of exterior angle 1210 between a nose 1610 and a tail 1620 (FIGS. 1-3) when coupled with first and second smoothing plates 1100 and 1200. In an example, blade 1600 is coupled with first and second smoothing plates 1100 and 1200 with three fasteners.

Nose 1610 of blade 1600 may be configured with a taper and an approach contour 1612 to resemble a ship's prow and may at least partly precede first and second smoothing plates 1100 and 1200 when coupled therewith. In an example, nose 1610 of blade 1600 may project away from first and second smoothing plates 1100 and 1200 along a line coincident with crest 1215 (FIG. 3). Blade 1600 may further include first and second side surfaces 1640 and 1650 extending between nose 1610 and tail 1620.

In an example, nose 1610 of blade 1600 may have an approach contour 1612 with radius of curvature when viewed from the side of about 0.50 inches (FIG. 6B) and an edge 1630 with a radius of curvature 0.093 inches when viewed from the front or rear (FIG. 6C). First and second sides 1640 and 1650 may form an angle of about 26 degrees therebetween. Blade 1600 may have a width of about 0.50 inches, a height of about 0.75 inches and a length of about 6.93 inches. Nose 1610 of blade 1600 may taper at about 75 degrees from either side of blade 1600 as viewed from the top or bottom of blade 1600 (FIG. 6A) such that an angle between facets 1614 and 1616 forming the taper measures about 30 degrees. The top of blade 1600 may further include an elongate concavity 1660 in the form of a concave channel having an internal radius of curvature of about 0.25 inches. Elongate cavity 1660 facilitates coupling of blade 1600 with smoothing plates 1100 and 1200 by conforming, at least partly, with exterior angle 1110.

Blade 1600 may be formed from or otherwise include any of a plurality of materials including but not limited to aluminum, plastics, steel, bronze and combinations thereof.

When blade 1600 is coupled with first and second smoothing plates 1100 and 1200, a longitudinal plane through edge 1630 of blade 1600 and crest 1215 of exterior angle 1210 extends at an angle of about 45 degrees to each of first and second smoothing plates 100 and 1200 as well as bisects exterior and interior angles 1110 and 1210. As a result of this arrangement and the angle of first side 1640 of blade 1600, when blade 1600 is coupled with first and second smoothing plates 1100 and 1200 and viewed from the front or back, first side 1640 of blade 1600 extends at an acute angle to first smoothing plate 1100 and at a complimentary angle to second smoothing plate 1200. Further, when blade 1600 is coupled with first and second smoothing plates 1100 and 1200 and viewed from the front or back, second side 1650 of blade 1600 extends at an acute angle to second smoothing plate 1200 and a complimentary angle to first smoothing plate 1100. The acute angle may measure from about 25 degrees to about 35 degrees. As such, the complimentary angle may measure from about 55 degrees to about 65 degrees.

In an example, when blade 1600 is coupled with first and second smoothing plates 1100 and 1200, first side 1640 of blade 1600 extends at an angle measuring about 32 degrees to first smoothing plate 1100 and about 58 degrees to second smoothing plate 1200. In this example, it follows that when blade 1600 is coupled with first and second smoothing plates 1100 and 1200, second side 1650 of blade 1600 extends at an angle measuring about 32 degrees to second smoothing plate 1200 and about 58 degrees to first smoothing plate 1100.

In another example, when blade 1600 is coupled with first and second smoothing plates 1100 and 1200, first side 1640 of blade 1600 extends at an angle measuring about 27.4 degrees to first smoothing plate 1100 and about 62.6 degrees to second smoothing plate 1200. In this example, it follows that when blade 1600 is coupled with first and second smoothing plates 1100 and 1200, second side 1650 of blade 1600 extends at an angle measuring about 27.4 degrees to second smoothing plate 1200 and about 62.6 degrees to first smoothing plate 1100.

Referring to FIG. 7, components described herein may comprise a joint-forming system 2000. Joint-forming system 2000 may include a plurality of blades of different configurations 1600 and 2600 which are interchangeable according to the desired size and/or shape of the joints to be formed. While the first and second blades may be provided in any of a variety of shapes and dimensions, in an example, the first blade 1600 takes the dimensions set forth above. Each of the plurality of blades of the system may be configured to extend along exterior angle 1210 at a crest 1215 thereof when coupled with first and second smoothing plates 1100 and 1200, for example, by one or more fasteners.

Another example interchangeable blade may have a nose with an approach contour with a radius of curvature when viewed from the side of about 0.50 inches may have an edge with a radius of curvature 0.094″ when viewed from the front or rear, may have first and second sides forming an angle of about 35 degrees therebetween, may have a width of about 0.686 inches, may have a height of about 0.864 inches, may have a nose that taper at about 75 degrees from either side of the blade as viewed from the top or bottom of the blade such that an angle between facets forming the taper measures about 30 degrees and the blade may have a length of about 7.00 inches. The top of another example blade may further include a elongate concavity having an internal radius of curvature of about 0.25 inches and an angle of about 45 degrees between internal sidewalls.

FIG. 8 illustrates an example method of manufacturing a joint-forming apparatus. The method includes, from a construction material, cutting a blade to a first length at 3100. The blade may then be milled a second length shorter than the first length, as necessary. Nose angles are milled at the nose of the blade at 3200. An elongate concavity is milled in a top of the blade at 3300. The first and second side angles are milled into the blade at 3400. In an example, the first and second sides and are milled consecutively rather than concurrently. A radius is milled into the bottom of the blade at 3500 to form a rounded edge. At 3600 a radius is milled into the nose of the blade.

First and second brackets are coupled to first and second smoothing plates at 3700. In an integral example, first and second brackets form a single piece with interior and exterior angles to which the first and second brackets are coupled. In a multi-piece example, first and second smoothing plates may be coupled to one another before coupling with the first and second brackets or the first and second brackets may serve to couple the first and second smoothing plates together forming interior and exterior angles.

A handle is coupled between the brackets at 3800 and a blade is coupled to the first and second smoothing plates 3900 to complete assembly of a joint-forming tool. The blade may be coupled with the smoothing plates and the handle coupled with between the brackets by one or more fasteners such as threaded fasteners. In an example, the blade is coupled with the first and second smoothing plates at three tapped bores provided to the blade at the elongate concavity such that the blade extends along the exterior angle at a crest thereof. In an example, the handle and brackets may be provided as one integral piece.

In an example, the blade may be cut from the construction material to a 7.125 inch length, the blade is milled to a length of 7.0 inches, the nose angles at a nose of the blade are milled to 15 degrees, the 0.449 inch wide concavity is milled in the top of the blade to a 0.25 inch radius, the first side angle is milled to 13 degrees, the a second side angle is milled to 13 degrees, the bottom of the blade is milled so as to have a 0.093 inch radius; and the nose of the blade is milled so as to have a 0.5 inch radius.

In another example, is milled to a length of 6.93 inches, the nose angles at a nose of the blade are milled to 15 degrees, the concavity is milled in the top of the blade to a 0.25 inch radius with two 45 degree interior walls, the first side angle is milled to 17.6 degrees, the second side angle is milled to 17.6 degrees, the bottom of the blade is milled so as to have a 0.094 inch radius and the nose of the blade is milled so as to have an approach contour with a 0.5 inch radius of curvature.

The actions described with reference to FIG. 8 regarding manufacture of a joint-forming apparatus and/or system are only illustrative and other alternatives can also be provided where one or more actions are added, one or more actions are removed, or one or more actions are provided in a different sequence without departing from the scope of the claims herein.

FIG. 9 illustrates example use of disclosed joint-forming apparatus. With disclosed apparatus 1000 and/or system 2000 a user carves into the full horizontal length of a newly-poured concrete step to create a joint at the 90-degree angle where the riser 4100 meets tread 4200. The user holds apparatus 1000 and presses down into the concrete at the 90-degree angle of the step with smoothing plate 1100 on the surface of tread 4200 and smoothing plate 1200 on the surface of riser 4100 and slides the apparatus 1000 in forward and backward motions until the joint 4400 is sufficiently and smoothly carved into the interface 4300 of tread 4200 and riser 4100 and reaches the desired depth. In an example, the joint is formed to a depth of 0.50 inches. In the event the user desires a differently shaped joint cross-section or a different depth joint, the user may interchange a first blade with a second blade, for example, by decoupling the first blade from the smoothing plates 1100 and 1200 and then coupling the second blade with the smoothing plates 1100 and 1200. As described above, coupling of blades with the smoothing plates 1100 and 1200 may be accomplished by way of example with treaded fasteners.

The actions described with reference to FIG. 9 regarding example use are only illustrative and other alternatives can also be provided where one or more actions are added, one or more actions are removed, or one or more actions are provided in a different sequence without departing from the scope of the claims herein.

Modifications to embodiments of the disclosure described in the foregoing are possible without departing from the scope of the disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “consisting of”, “have”, “is” used to describe and claim disclosed features are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. 

What is claimed is:
 1. A joint-forming apparatus, comprising a first smoothing plate; a second smoothing plate coupled with the first smoothing plate so as to form an interior angle and an exterior angle therewith; a first bracket extending between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle; a second bracket extending between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle; a handle extending between the first bracket and the second bracket; and a blade extending along the exterior angle at a crest thereof.
 2. The joint-forming apparatus as set forth in claim 1, wherein the blade extends from a nose preceding the first and second smoothing plates along the crest to a tail.
 3. The joint-forming apparatus as set forth in claim 2, wherein the nose of the blade projects away from the first and second smoothing plates along a line coincident with the crest.
 4. The joint-forming apparatus as set forth in claim 2, wherein the nose of the blade comprises a taper.
 5. The joint-forming apparatus as set forth in claim 2, wherein the blade further comprises first and second side surfaces extending between the nose and tail.
 6. The joint-forming apparatus as set forth in claim 5, wherein the blade first side surface extends at an acute angle to the first smoothing plate and extends at a complimentary angle to the second smoothing plate.
 7. The joint-forming apparatus as set forth in claim 6, wherein the blade second extends at an acute angle to the second smoothing plate and extends at a complimentary angle to the first smoothing plate.
 8. A joint-forming system, comprising: a first smoothing plate; a second smoothing plate coupled with the first smoothing plate so as to form an interior angle and an exterior angle therewith; a first bracket extending between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle; a second bracket extending between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle; a handle extending between the first bracket and the second bracket; and a first blade configured to extend along the exterior angle at a crest thereof.
 9. The joint-forming system as set forth in claim 8, further comprising a second blade configured to extend along the exterior angle at the crest and having dimensions different from dimensions of the first blade such that the first and second blades are interchangeable to form joints of different dimensions.
 10. The joint-forming system as set forth in claim 8, wherein the first blade is further configured such that a nose thereof precedes the first and second smoothing plates when the blade extends along the crest.
 11. The joint-forming system as set forth in claim 10, wherein the nose of the blade projects away from the first and second smoothing plates along a line coincident with the crest when the blade extends along the crest.
 12. The joint-forming system as set forth in claim 10, wherein the nose of the blade comprises a taper.
 13. The joint-forming apparatus as set forth in claim 10, wherein the blade further comprises a tail and first and second side surfaces extending between the nose and the tail and the first side surface extends at an acute angle to the first smoothing plate and extends at a complimentary angle to the second smoothing plate.
 14. The joint-forming apparatus as set forth in claim 13, wherein the second side surface extends at an acute angle to the second smoothing plate and extends at a complimentary angle to the first smoothing plate.
 15. A method for manufacturing a joint-forming apparatus, comprising: from a construction material, cutting a blade to a first length; milling nose angles into a nose of the blade; milling an elongate concavity in a top of the blade; milling an angled first side into the blade; milling an angled second side into the blade; milling a radius into a bottom edge of the blade; milling a radius into the nose of the blade; coupling a first smoothing plate with a second smoothing plate so as to form an interior angle and an exterior angle therebetween; and coupling the blade to the first and second smoothing plates.
 16. The method as set forth in claim 15, wherein coupling the blade to the first and second smoothing plates further comprises coupling such that the nose of the blade projects away from the first and second smoothing plates along a line coincident with a crest of the exterior angle.
 17. The method as set forth in claim 15, wherein coupling the blade to the first and second smoothing plates further comprises coupling such that the first side of the blade extends at an acute angle to the first smoothing plate and a complimentary angle to the second smoothing plate and such that the second side of the blade extends at an acute angle to the second smoothing plate and a complimentary angle to the first smoothing plate.
 18. The method as set forth in claim 15, wherein milling the radius into the nose of the blade further comprises milling form a taper.
 19. The method as set forth in claim 15, further comprising extending a first bracket between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle and extending a second bracket between the first smoothing plate and the second smoothing plate so as to span a portion of the interior angle.
 20. The method as set forth in claim 19, further comprising coupling a handle between the first bracket and the second bracket. 